Fiber reinforced systems with electrostatic dissipation

ABSTRACT

Systems and methods of forming fiber reinforced polymer (FRP) composites with electrostatic dissipative properties are described herein. The FRP composite is bonded to a surface and integrates a grounding system to dissipate electro-static energy, thus eliminating the potential risk of explosion. The system can be used for structures that require reinforcement and that are susceptible to electro-static explosions.

CROSS REFERENCE

This application claims benefit of U.S. Provisional Application No.62/418,600 filed Nov. 7, 2016, the specification of which isincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a fiber reinforced polymer (FRP)systems with electrostatic dissipative (ESD) properties, and methods ofusing said systems on various substrates.

BACKGROUND OF THE INVENTION

Explosions can occur when fuel sources such as gas, vapors, mists, ordusts are ignited from sources like static electricity. Infrastructureassets that operate in these conditions are typically designed inaccordance with NFPA 69: Standard on Explosion Prevention Systems.Currently, conductive coatings with ESD capabilities are applied as asecondary coating on existing surfaces to dissipate static. Saidsurfaces may be part of non-structural systems, such as electronicequipment, or flooring and flooring materials, such as concretesurfaces, tiles, carpet, and floor mats. However, these ESD coatings areused typically used for non-structural systems, but have not beenapplied to primary structural systems.

These structures, such as walls and pillars, often require repairs thatcan be installed using “cold” or non-welded solutions. Until now,composite repair systems cannot dissipate the static electricity thatcan build up during operations. Composites are natural insulators andtherefore can hold accumulate static. The release of static can ignitecombustible dust, which will create significant asset damage, and mayresult in loss of lives. This invention imparts ESD properties in fiberreinforced polymer composites designed for structural reinforcement,which allows for static to dissipate to ground via the ESD propertiesthat would be in contact with static accumulation, thereby preventingloss of lives and protecting assets in environments where staticelectricity can ignite combustible dusts.

Any feature or combination of features described herein are includedwithin the scope of the present invention provided that the featuresincluded in any such combination are not mutually inconsistent as willbe apparent from the context, this specification, and the knowledge ofone of ordinary skill in the art. Additional advantages and aspects ofthe present invention are apparent in the following detailed descriptionand claims.

SUMMARY OF THE INVENTION

It is an objective of the present invention to provide for a non-weldedrepair solution that can strengthen and reinforce a structure as well asdissipate static electricity to a structure's grounding source. It is afurther objective of the invention to restore structural integrity to acritical asset and maintain NFPA 69 compliance. Thus, in one aspect, thepresent invention features a system comprising a fiber reinforcedpolymer (FRP) composite, a conductive filler material disposed in theFRP composite, a conductive network in contact with or disposed withinthe FRP composite, and a grounding component connected to the conductivenetwork.

In some aspects, the present invention features a fiber reinforcedpolymer (FRP) system having a conductive filler material, which candecrease the ohm's resistance of said system in the insulate range ofabout ≥1.0×10¹¹ ohms. Said conductive filler material is embedded withinthe structural reinforcing FRPs of the invention and then tied to agrounding source, thus achieving electrostatic dissipation (ESD). Thisallows for static to dissipate to conductive copper strips, or otherequivalent conductive or metallic material, which then transfers thestatic to a grounding source, thereby rendering it harmless forignition. The invention can be designed for strengthening a structure towithstand explosions Class A rating for ASTM E84 Flame & Smoke SpreadIndex System, and can be further designed for up to a 3-hour fireresistance rating per ASTM E119. None of the presently known priorreferences or work has the unique inventive technical feature of thepresent invention. Current ESD materials in the art have not beenapplied to primary structural systems; instead, they are typically inthe form of ESD coatings used for non-structural systems.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention will becomeapparent from a consideration of the following detailed descriptionpresented in connection with the accompanying drawings in which:

FIG. 1 shows a non-limiting embodiment of a fiber reinforced polymer(FRP) composite of the present invention.

FIG. 2 shows a non-limiting example of a conducting network disposed ona surface of a structure or on a layer of an FRP composite.

FIG. 3 shows a non-limiting embodiment of a reinforcing andelectrostatic dissipative (ESD) composite system of the presentinvention

FIGS. 4A-4F show cross-sectional views of non-limiting embodiments ofthe FRP composite in which the conducting network is located indifferent layers of the FRP composite.

FIGS. 5A-5B show non-limiting embodiments of the FRP composite in whichthe conducting network is a component of a reinforcing fabric ply.

DESCRIPTION OF PREFERRED EMBODIMENTS

Following is a list of elements corresponding to a particular elementreferred to herein:

-   -   10 structure    -   15 surface of structure    -   100 reinforcing and electrostatic dissipative (ESD) composite        system    -   110 fiber reinforced polymer (FRP) composite    -   112 base coating    -   114 polymer resin composition    -   116 top coating    -   120 reinforcing ply stack    -   122 reinforcing fabric ply    -   124 pocket    -   125 pocket seam edge    -   126 fiber tow    -   128 filaments    -   130 conductive filler material    -   140 conductive network    -   142 conductive wiring or tape    -   144 conductive thread    -   145 grid pattern    -   150 connection clip    -   160 grounding component

Dissipative materials allow the charges to flow to ground more slowly ina more controlled manner than with conductive materials. Materialsconsidered to be static dissipative have a surface resistance of 1.0×10⁴ohms to <1.0×10¹¹ ohms and allow for dissipation of electrical chargesgenerally within milliseconds.

In some embodiments, the fiber reinforced polymer (FRP) of the presentinvention may be according to the systems described in U.S. Pat. Nos.8,696,849 and 9,307,796 of Butler, the specifications of which areincorporated herein by reference. Briefly, U.S. Pat. Nos. 8,696,849 and9,307,796 teach novel reinforcement systems for maximizing tensilestrength and modulus of elasticity per ply for composite systems. A plyof reinforcement fabric has a first fabric edge seam that traverses andbinds the fabric parallel and adjacent to a first fabric edge, and asecond fabric edge seam that traverses and binds the fabric parallel toand adjacent to a second fabric edge. The first and second fabric edgestraverse the fabric in the direction of an X-axis (0 degrees). Thefabric may have one or more pockets with a first pocket edge, a secondpocket edge, a pocket front surface, and a pocket rear surface. Thepocket front surface and the pocket rear surface each have a pocketcross-stitch that perpendicularly traverses the pocket. A first pocketseam has stitching in a plane defined by the X-axis (0 degrees) and aZ-axis alternatingly attaching the pocket front surface to the pocketrear surface via the stitching. The pocket traverses the fabric paralleland adjacent to the first fabric edge and the second fabric edge in awarp, or 0 degree, or x-axis direction. The pockets contain one or morefiber tows with a plurality of filaments in a stack.

Referring now to FIGS. 1-5B, the present invention features areinforcing and electrostatic dissipative (ESD) composite system (100)comprising a fiber reinforced polymer (FRP) composite (110), aconductive filler material (130), a conductive network (140) of wires ortape, and a grounding wire (160) connected to the conductive network(140) via a connection clip (150). In some embodiments, the fiberreinforced polymer (FRP) composite (110) may comprise a base coating(112) configured to be applied on a surface (15) of a structure (10), areinforcing ply stack (120) disposed on the base coating (112), apolymer resin composition (114) applied on the ply stack (120) andsaturating each fabric ply (122), and a top coating (116) disposed onthe saturated ply stack (120). In other embodiments, the ply stack (120)may comprise one or more reinforcing fabric plies (122), each fabric ply(122) being layered atop another fabric ply (122) to form the ply stack(120). Each fabric ply (122) may comprise a plurality of linear pockets(124) aligned in parallel, where each pocket (124) is stitchedlengthwise to its neighboring pockets (124) at a pocket seam edge (125),and a fiber tow (126) comprising a plurality of filaments (128)collected into a bundle, and being disposed lengthwise in each pocket(124). In one embodiment, the conductive filler material (130) may bedisposed, e.g. embedded, in the top coating (116) of the FRP composite.In another embodiment, the conductive network (140) of wires or tape maybe juxtaposed between the saturated ply stack (120) and the top coating(116) with the conductive filler material (130).

According to another embodiment of the present invention, the system(100) may comprise a fiber reinforced polymer (FRP) composite (110), aconductive filler material (130) disposed in the FRP composite (110), aconductive network (140) of wires or tape in contact with or disposedwithin the FRP composite (110), and a grounding component (160)connected to the conductive network (140). In some embodiments, the FRPcomposite (110) may comprise a base coating (112) configured to beapplied on a surface (15) of the structure (10), a reinforcing ply stack(120) disposed on the base coating (112) and comprising one or morereinforcing fabric plies (122) being layered atop each other to form theply stack (120), a polymer resin composition (114) applied on the plystack (120) and saturating each fabric ply (122), and a top coating(116) disposed on the saturated ply stack (120). In other embodiments,each fabric ply (122) may comprise a plurality of linear pockets (124)aligned in parallel, with each pocket (124) being stitched lengthwise toits neighboring pockets (124) at a pocket seam edge (125), and a fibertow (126) comprising a plurality of filaments (128) collected into abundle and disposed lengthwise in each pocket (124).

Without wishing to bind the invention to a particular theory ormechanism, when any system (100) is disposed on the surface ofstructure, the FRP composite (110) may be effective for reinforcing thestructure (10). Further still, the conductive filler material (130) maybe effective for dissipating static from the structure (10) and the FRPcomposite (110) to the grounding wire (160) via the conductive network(140), thereby reducing a risk of static ignition. Preferably, thesystem (100) can have a resistivity in a static dissipative range ofabout 1.0×10⁴ to <1.0×10¹¹ ohms, per ANSI ESD S541 ResistanceClassification, which falls in the static dissipating range.

In one embodiment, the base coating (112) may comprise a primercomponent applied on the surface of the structure, and a base componentapplied on the primer component. In another embodiment, the polymerresin composition (114) may comprise a resin component and an activationcomponent. In some embodiments, the resin component may be anythermosetting polymer including, but not limited to, epoxies, urethanes,vinyl esters, and phenol formaldehyde resins such as novolac. In otherembodiments, the activation component may be a hardener or catalyst. Infurther embodiments, the top coating (116) may be any thermosettingpolymer.

In still another embodiment, the pockets (124) and filaments (128) maybe constructed from polyethylene, glass, basalt, aramid, and carbon. Insome embodiments, the fiber tow has about 1-3,000 filaments. In otherembodiments, the fiber tow has about 3,000-6,000 filaments, or about6,000-12,000 filaments, or about 12,000-50,000 filaments. In furtherembodiments, the fiber tow has more than about 50,000 filaments, or morethan about 100,000 filaments, or more than about 400,000 filaments. Infurther embodiments, the filaments may be non-interlaced filaments,interlaced filaments, non-twisted filaments, or twisted filaments.

In some embodiments, the cross-sectional area of the filament bundle isabout 50% to 70% of the cross-sectional area of the pocket. In otherembodiments, the cross-sectional area of the filament bundle is about70% to 85% of the cross-sectional area of the pocket. In furtherembodiments, the cross-sectional area of the filament bundle is about85% to 99.5% of the cross-sectional area of the pocket.

In some embodiments, the volume of the filament bundle is about 50% to70% of the volume of the pocket. In other embodiments, the volume of thefilament bundle is about 70% to 85% of the volume of the pocket. Infurther embodiments, the volume of the filament bundle is about 85% to99.5% of the volume of the pocket.

In one embodiment, the conductive filler material (130) may be in theform of a powder. Non-limiting examples of the conductive fillermaterial (130) include graphite, carbon fiber, carbon powder, carbonnanotubes, and metallic powder. In another embodiment, the groundingcomponent (160) may be constructed from a conductive material such ascopper, silver, gold, or alloys thereof. In some embodiments, thegrounding component (160) may comprise at least one ground wire that isconnected to the conductive network (140) via the connection clip (150).In other embodiments, the ground wires or ties, which are attached tothe conductive metal strips, can be configured such that one groundingwire extends from a first outer edge of the system, and another wireextends from an opposing outer edge.

In some embodiments, the conductive filler material (130) may be mixedwith at least one of the base coating (112), the polymer resincomposition (114), or the top coating (116) to form an ESD layer. TheESD layer may comprise about 5%-70% vol of the conductive fillermaterial (130). For example, the ESD layer may comprise about 5%-15% volof the conductive filler material (130), or about 10%-25% vol of theconductive filler material (130), or about 20%-40% vol of the conductivefiller material (130), or about 30%-50% vol of the conductive fillermaterial (130), or about 40%-60% vol of the conductive filler material(130), or about 50%-70% vol of the conductive filler material (130).

In one embodiment, as shown in FIG. 4F, the conductive filler material(130) may be mixed with the base coating (112), and the conductivenetwork (140) is disposed on the surface of the structure such that theconductive network (140) is directly in contact with the ESD layer.Alternatively, as shown in FIGS. 4D and 4E, the conductive fillermaterial (130) may be mixed with the base coating (112) or polymer resincomposition (114), and the conductive network (140) is disposed on thebase coating (112) such that the conductive network (140) is directly incontact with the ESD layer. In another alternative example, as shown inFIG. 4A, the conductive filler material (130) may be mixed with thepolymer resin composition (114) or the top coating (116), and theconductive network (140) is disposed on the reinforcing ply stack (120)such that the conductive network (140) is directly in contact with theESD layer. In further embodiments, example, as shown in FIGS. 4B and 4C,the conductive filler material (130) may be mixed with the polymer resincomposition (114), and the conductive network (140) is disposed withinthe reinforcing ply stack (120), e.g. layered between two fabric plies,such that the conductive network (140) is directly in contact with theESD layer.

In other embodiments, the conductive filler material (130) may be an ESDlayer juxtaposed between at least two layers of the FRP composite.Preferably, the conductive network (140) is disposed between the sametwo layers of the FRP composite such that the conductive network (140)is directly in contact with the ESD layer. In one embodiment, the ESDlayer may be a thin layer of conductive powder substantially covering asurface of one layer. For example, the conductive powder may be appliedon the surface of the outermost fabric ply to form the ESD layer, andthe conductive network (140) is installed on the ESD layer, after whichthe top coating (116) is applied. As another example, the conductivepowder may be applied on the surface of the base coating (112) to formthe ESD layer, and the conductive network (140) is installed on the ESDlayer, after which a fabric ply is applied.

According to one embodiment, the conductive network (140) may comprise aconductive metal in the form of a tape, ribbon, or wire. Said conductingmetal may be connected to a ground wire. In some embodiments, theconductive metal tape, wire, or other conductive substrate are dividedinto strips and arranged in a grid pattern. Each grid of the gridpattern can have a length and width that is calculated based on theconductivity of the surface exposed to static electricity. For example,the system may be set in a grid based on a conservative configuration,and knowing that static would not travel far before hitting the “tie toground source”. However, it is understood that the spacing is not afixed requirement for the system and may be determined based on specificstructural and conductivity requirements. The conductive “tie to ground”can be anything that is conductive and can be bonded over using apolymer from the system of the present invention.

In an alternative embodiment, the conductive network (140) may compriseconductive thread (144) used for stitching together the pocket seam edge(125) of two neighboring pockets (124), as shown in FIG. 5A. In yetanother alternative embodiment, the pockets (124) or filaments (128) maybe constructed from a conductive material such as carbon fiber, copper,silver, steel and aluminum. Without wishing to limit the invention to aparticular theory or mechanism, with this conductive material ofconstruction, the pockets (124) or filaments (128) can effectively formthe conductive network (140), as shown in FIG. 5B.

In one embodiment, the system may be disposed on a structure, such as astructure that may require repair or reinforcement. Further still, thestructure may be prone to accumulating static and electrostaticexplosions. Examples of said structures may include, but are not limitedto, elevator grain pipes, tanks and vessels, grain and coal silos,hoppers and containers, grain chutes, or any other structure wherefriction from media interfacing with the surface causes electrostaticenergy that can result in an explosion. In another embodiment, thestructures may be constructed from concrete, steel, masonry, wood,plastic, an insulative material, or any other material that canaccumulate static.

Since the system may be used to reinforce and dissipate static from astructure, the present invention also provides for methods ofreinforcing and dissipating static from the structure. In oneembodiment, the method may comprise providing any one of the reinforcingand electrostatic dissipative systems described herein, attaching saidsystem to an outer surface of the structure, and connecting thegrounding component to a ground source.

According to another embodiment, the method may comprise providing afiber reinforced polymer (FRP) composite (110) comprising a base coating(112); one or more reinforcing fabric plies (122), each fabric ply (122)comprising a plurality of linear pockets (124) aligned in parallel,where each pocket (124) is stitched lengthwise to its neighboringpockets (124) at a pocket seam edge (125), and a fiber tow (126)comprising a plurality of filaments (128) collected into a bundle anddisposed lengthwise in each pocket (124); a polymer resin composition(114); and a top coating (116). The method may further compriseproviding a conductive filler material (130); providing conductivewiring or tape (142); providing a connection clip (150) and a groundingcomponent (160); preparing the structure (10) for application of the FRPcomposite (110); mixing the conductive filler material (130) with thetop coating (116); applying the base coating (112) to a surface (15) ofthe prepared structure (10); applying the one or more reinforcing fabricplies (122) over the prepared structure (10) by laying the fabric ply(122) on the base coating (112) and applying and saturating the fabricply (122) with the polymer resin composition (114); applying theconductive wiring or tape (142) on an outermost layer of fabric ply(122) to form a conductive network (140); applying the top coating (116)having the conductive filler material (130) on the outermost layer offabric ply (122) and the conductive network (140); connecting theconductive network (140) to the grounding component (160) via theconnection clip (150), thus forming a reinforcing and ESD compositesystem; and connecting the grounding component (160) to a ground source.In some embodiments, the conductive wiring or tape (142) may be dividedinto strips and arranged in a grid pattern (145).

According to yet another embodiment, the method may comprise providingan FRP composite (110) comprising a base coating (112); one or morereinforcing fabric plies (122), each fabric ply (122) comprising aplurality of linear pockets (124) aligned in parallel, where each pocket(124) is stitched lengthwise to its neighboring pockets (124) at apocket seam edge (125), and a fiber tow (126) comprising a plurality offilaments (128) collected into a bundle and disposed lengthwise in eachpocket (124); a polymer resin composition (114); and a top coating(116). The method may further comprise providing a conductive fillermaterial (130); providing conductive wiring or tape (142); providing aconnection clip (150) and a grounding component (160); preparing thestructure (10) for application of the FRP composite (110); mixing theconductive filler material (130) with at least one of the base coating(112), the polymer resin composition (114), or the top coating (116);applying the base coating (112) to a surface (15) of the preparedstructure (10); applying the one or more reinforcing fabric plies (122)over the prepared structure (10) by laying the fabric ply (122) on thebase coating (112), and applying and saturating the fabric ply (122)with the polymer resin composition (114); applying the top coating (116)on an outermost layer of fabric ply (122); installing the conductivewiring or tape (142) to form a conductive network (140) such that theconductive wiring or tape (142) is disposed between at least one layerof the FRP composite (110) and is directly in contact with theconductive filler material (130) mixed with the base coating (112), thepolymer resin composition (114), or the top coating (116); connectingthe conductive network (140) to the grounding component (160) via theconnection clip (150), thus forming a reinforcing and ESD compositesystem; and connecting the grounding component (160) to a ground source.In other embodiments, the conductive wiring or tape (142) may be dividedinto strips and arranged in a grid pattern (145).

In one embodiment, the conductive filler material (130) may be mixedwith the base coating (112) to form an ESD layer, and the conductivenetwork (140) may be disposed on the surface (15) of the preparedstructure (10) such that the conductive network (140) is directly incontact with the ESD layer. In another embodiment, the conductive fillermaterial (130) may be mixed with the base coating (112) or polymer resincomposition (114) to form an ESD layer, and the conductive network (140)may be disposed on the base coating (112) such that the conductivenetwork (140) is directly in contact with the ESD layer. In a furtherembodiment, the conductive filler material (130) may be mixed with thepolymer resin composition (114) or the top coating (116) to form an ESDlayer, and the conductive network (140) may be disposed on the outermostlayer of fabric ply (122) such that the conductive network (140) isdirectly in contact with the ESD layer.

According to a further embodiment, the method may comprise providing afiber reinforced polymer (FRP) composite (110) comprising a base coating(112); one or more reinforcing fabric plies (122), each fabric ply (122)comprising a plurality of linear pockets (124) aligned in parallel,where each pocket (124) is stitched lengthwise to its neighboringpockets (124) at a pocket seam edge (125), a fiber tow (126) comprisinga plurality of filaments (128) collected into a bundle and disposedlengthwise in each pocket (124), and a conductive network (140); apolymer resin composition (114); and a top coating (114). The method mayalso comprise providing a conductive filler material (130); providing aconnection clip (150) and a grounding component (160); preparing thestructure (10) for application of the FRP composite (110); mixing theconductive filler material (130) with at least one of the base coating(112), the polymer resin composition (114), or the top coating (116);applying the base coating (112) to a surface (15) of the preparedstructure (10); applying the one or more reinforcing fabric plies (122)over the prepared structure (10) by laying the fabric ply (122) on thebase coating (112) and applying and saturating the fabric ply (122) withthe polymer resin composition (114); applying the top coating (116) onan outermost layer of fabric ply (122); connecting the conductivenetwork (140) to the grounding component (160) via the connection clip(150), thus forming a reinforcing and ESD composite system; andconnecting the grounding component (160) to a ground source.

In one embodiment, the conductive network (140) may comprise conductivethread (144) used for stitching together the pocket seam edge (125) oftwo neighboring pockets (124). In another embodiment, the pockets (124)or filaments (128) may be constructed from the conductive material, thuseffectively forming the conductive network (140). In a preferredembodiment, the conductive material may be carbon fiber, copper, silver,steel, or aluminum.

In another embodiment, the step of preparing the structure may comprisecleaning the structure. In addition, cracks in the structure may bepatched or the surface re-leveled. For instance, loose particles, scale,surface oxidation, and oily films may be removed via physical abrasionor power washing.

In further embodiments, the step of layering the one or more reinforcingfabric plies (122) over the prepared structure (10) may further compriselaying the fabric ply (122) on a previous layer of saturated fabric ply(122), applying and saturating the overlying fabric ply (122) with thepolymer resin composition (114), and repeating said steps until adesired thickness of stacked reinforcing fabric plies (122) is achieved.For example, the steps may be repeated as needed so as to form a stackof reinforcing fabric plies (122) ranging from about 2 to 10 plies inthe stack. The thickness can also vary from 0.5-3 inches.

In some embodiments, the grounding component (160) may comprise at leastone ground wire, connected to the conductive network (140) via aconnection clip (150). In other embodiments, the step of connecting thegrounding component (160) to a ground source, such as an environmentalground, may comprise burying the ground component underground, e.g. insoil or dirt.

Without wishing to bind the invention to a particular theory ormechanism, the methods described herein effectively allows for the FRPcomposite (110) to reinforce the structure when the polymer resincomposition (114) is cured. Furthermore, the conductive filler material(130) imparts ESD properties in the FRP composite (110), thuseffectively dissipating static from the structure (10) and the FRPcomposite (110) to the grounding component (160) via the conductivenetwork (140), thereby reducing a risk of static ignition. Preferably,the system (100) can have a resistivity in a static dissipative range ofabout 1.0×10⁴ to <1.0×10¹¹ ohms, per ANSI ESD S541 ResistanceClassification, which falls in the static dissipating range.

As used herein, the term “about” refers to plus or minus 10% of thereferenced number.

The disclosures of the following U.S. patents are incorporated in theirentirety by reference herein: U.S. Pat. Nos. 8,696,849 and 9,307,796.

Various modifications of the invention, in addition to those describedherein, will be apparent to those skilled in the art from the foregoingdescription. Such modifications are also intended to fall within thescope of the appended claims. Each reference cited in the presentapplication is incorporated herein by reference in its entirety.

Although there has been shown and described the preferred embodiment ofthe present invention, it will be readily apparent to those skilled inthe art that modifications may be made thereto which do not exceed thescope of the appended claims. Therefore, the scope of the invention isonly to be limited by the following claims. Reference numbers recited inthe claims are exemplary and for ease of review by the patent officeonly, and are not limiting in any way. In some embodiments, the figurespresented in this patent application are drawn to scale, including theangles, ratios of dimensions, etc. In some embodiments, the figures arerepresentative only and the claims are not limited by the dimensions ofthe figures. In some embodiments, descriptions of the inventionsdescribed herein using the phrase “comprising” includes embodiments thatcould be described as “consisting of”, and as such the writtendescription requirement for claiming one or more embodiments of thepresent invention using the phrase “consisting of” is met.

1. A reinforcing and electrostatic dissipative (ESD) composite system(100) comprising: a. a fiber reinforced polymer (FRP) composite (110)comprising: i. a base coating (112) configured to be applied on asurface (15) of a structure (10); ii. a reinforcing ply stack (120)disposed on the base coating (112), wherein the ply stack (120)comprises one or more reinforcing fabric plies (122), each fabric ply(122) being layered atop another fabric ply (122) to form the ply stack(120), wherein each fabric ply (122) comprises a plurality of linearpockets (124) aligned in parallel, wherein each pocket (124) is stitchedlengthwise to its neighboring pockets (124) at a pocket seam edge (125);and a fiber tow (126) comprising a plurality of filaments (128)collected into a bundle, wherein the fiber tow (126) is disposedlengthwise in each pocket (124); iii. a polymer resin composition (114)applied on the ply stack (120) and saturating each fabric ply (122); andiv. a top coating (116) disposed on the saturated ply stack (120). b. aconductive filler material (130) disposed in the top coating (116) ofthe FRP composite; c. a conductive network (140) of wires or tapejuxtaposed between the saturated ply stack (120) and the top coating(116) with the conductive filler material (130); and d. a grounding wire(160) connected to the conductive network (140) via a connection clip(150); wherein when the system (100) is disposed on the surface ofstructure, the FRP composite (110) is effective for reinforcing thestructure (10), wherein the conductive filler material (130) iseffective for dissipating static from the structure (10) and the FRPcomposite (110) to the grounding wire (160) via the conductive network(140), thereby reducing a risk of static ignition.
 2. A reinforcing andelectrostatic dissipative (ESD) composite system (100) comprising: a. afiber reinforced polymer (FRP) composite (110); b. a conductive fillermaterial (130) disposed in the FRP composite (110); c. a conductivenetwork (140) of wires or tape in contact with or disposed within theFRP composite (110); and d. a grounding component (160) connected to theconductive network (140); wherein when the system (100) is disposed on astructure (10), the FRP composite (110) is effective for reinforcing thestructure (10), wherein the conductive filler material (130) iseffective for dissipating static from the structure (10) and the FRPcomposite (110) to the grounding component (160) via the conductivenetwork (140′, thereby reducing a risk of static ignition.
 3. The system(100) of claim 2, wherein the FRP composite (110) comprises: a. a basecoating (112) configured to be applied on a surface (15) of thestructure (10); b. a reinforcing ply stack (120) disposed on the basecoating (112), wherein the ply stack (120) comprises one or morereinforcing fabric plies (122), each fabric ply (122) being layered atopanother fabric ply (122) to form the ply stack (120), wherein eachfabric ply (122) comprises: i. a plurality of linear pockets (124)aligned in parallel, wherein each pocket (124) is stitched lengthwise toits neighboring pockets (124) at a pocket seam edge (125); and ii. afiber tow (126) comprising a plurality of filaments (128) collected intoa bundle, Wherein the fiber tow (126) is disposed lengthwise in eachpocket (124); c. a polymer resin composition (114) applied on the plystack (120) and saturating each fabric ply (122); and d. a top coating(6) disposed on the saturated ply stack (120).
 4. The system (100) ofclaim 3, wherein the base coating (112) comprises a primer componentapplied on the surface of the structure, and a base component applied onthe primer component.
 5. The system (100) of claim 3, wherein theconductive filler material (130) is in the form of a powder.
 6. Thesystem (100) of claim 5, wherein the conductive tiller material (130) ismixed with at least one of the base coating (112), the polymer resincomposition (114), or the top coating (116) to form an ESD layer.
 7. Thesystem (100) of claim 6, wherein the conductive filler material (130) ismixed with the base coating (112), and the conductive network (140) isdisposed on the surface of the structure such that the conductivenetwork (140) is directly in contact with the ESD layer.
 8. The system(100) of claim 6, wherein the conductive tiller material (130) is mixedwith the base coating (112) or polymer resin composition (114), and theconductive network (140) is disposed on the base coating (112) such thatthe conductive network (140) is directly in contact with the ESD layer.9. The system of claim 6, wherein the conductive filler material 3 mixedwith the polymer resin composition (114) or the top coating (116), andthe conductive network (140) is disposed on the reinforcing ply stack(120) such that the conductive network (140) is directly in contact withthe ESD layer.
 10. The system (100) of claim 5, wherein the conductivefiller material (130) forms an ESD layer juxtaposed between at least twolayers of the FRP composite, wherein the conductive network (140) isdisposed between said at least two layers of the FRP composite such thatthe conductive network (140) is directly in contact with the ESD layer.11. The system (100) of claim 1, wherein the conductive filler material(130) is selected from a group consisting of graphite, carbon fiber,carbon powder, carbon nanotubes, and metallic powder.
 12. The system(100) of claim 1, wherein the conductive network (140) comprisesconductive wiring or tape (142) divided into strips and arranged in agrid pattern (145).
 13. The system (100) of claim 3, wherein theconductive network (140) comprises conductive thread (144) used forstitching together the pocket seam edge (125) of two neighboring pockets(124).
 14. The system (100) of claim 1, wherein the filaments (128) areconstructed from a material selected from a group consisting ofpolyethylene, glass, basalt, aramid, and carbon.
 15. The system (100) ofclaim 3, wherein the pockets (124) or filaments (128) are constructedfrom a conductive material selected from a group consisting of carbonfiber, copper, silver, steel and aluminum.
 16. The system (100) of claim15, wherein the pockets (124) or filaments (128) constructed from theconductive material effectively form the conductive network (140). 17.The system (100) of claim 2, wherein the grounding component (160)comprises at least one ground wire, where the at least one ground wireis connected to the conductive network (140) via a connection clip(150).
 18. The system (100) of claim 1, wherein the system (100) has aresistivity in a static dissipative range of about 1.0×10⁴ to <1.0×10¹¹ohms.
 19. A method of reinforcing and dissipating static from astructure (10), said method comprising: a. providing a reinforcing andelectrostatic dissipative system (100) of claim 1; b. attaching thesystem (100) to the surface (15) of the structure (100); and c.connecting the grounding component (160) to a ground source.
 20. Amethod of reinforcing and dissipating static from a structure (10), saidmethod comprising: a. providing a fiber reinforced polymer (FRP)composite (110) comprising: i. a base coating (112); ii. one or morereinforcing fabric plies (122), each fabric ply (122) comprising aplurality of linear pockets (124) aligned in parallel, wherein eachpocket (124) is stitched lengthwise to its neighboring pockets (124) ata pocket seam edge (125); and a fiber tow (126) comprising a pluralityof filaments (128) collected into a bundle, wherein the fiber tow (126)is disposed lengthwise in each pocket (124); iii. a polymer resincomposition (114); and iv. a top coating (116); b. providing aconductive filler material (130); c. providing conductive wiring or tape(142); d. providing a connection clip (150) and a grounding component(160); e. preparing the structure (TO) for application of the FRPcomposite (110); f. mixing the conductive filler material (130) with thetop coating (116); g. applying the base coating (112) to a surface (15)of the prepared structure (10); h. applying the one or more reinforcingfabric plies (122) over the prepared structure (10), comprising: i.laying the fabric ply (122) on the base coating (112); and ii. applyingand saturating the fabric ply (122) with the polymer resin composition(114); i. applying the conductive wiring or tape (142) on an outermostlayer of fabric ply (122), wherein the conductive wiring or tape (142)is divided into strips and arranged in a grid pattern (145) to form aconductive network (140); j. applying the top coating (116) having theconductive filler material (130) on the outermost layer of fabric ply(122) and the conductive network (140); k. connecting the conductivenetwork (140) to the grounding component (160) via the connection clip(150), thus forming a reinforcing and ESD composite system; and l.connecting the grounding component (160) to a ground source; wherein theFRP composite (110) reinforces the structure when the polymer resincomposition (114) is cured, Wherein the conductive filler material (130)is effective for dissipating static from the structure (10) and the FRPcomposite (110) to the grounding component (160) via the conductivenetwork (140), thereby reducing a risk of static ignition. 21.-35.(canceled)